U.S. patent number 7,984,716 [Application Number 11/821,390] was granted by the patent office on 2011-07-26 for self-conforming sound attenuation earplug.
This patent grant is currently assigned to Kimberly-Clark Worldwide Inc.. Invention is credited to Scott Madison Belliveau, Sean S. Corbin, Steven Craig Gehling, Waihong Leong, Anne Clare Moser, Ricky Wayne Purcell.
United States Patent |
7,984,716 |
Purcell , et al. |
July 26, 2011 |
Self-conforming sound attenuation earplug
Abstract
A self-conforming sound attenuation earplug, including: a stem,
at least one support joined with the stem and extending radially
outward from the stem, and a shell engaging the support and
encircling the stem to form a space between the shell and the stem.
At least one of the support material and the shell material is a
deformable-resilient material.
Inventors: |
Purcell; Ricky Wayne
(Alpharetta, GA), Gehling; Steven Craig (Cumming, GA),
Leong; Waihong (Roswell, GA), Moser; Anne Clare
(Chicago, IL), Corbin; Sean S. (Morton Grove, IL),
Belliveau; Scott Madison (Plainfield, IL) |
Assignee: |
Kimberly-Clark Worldwide Inc.
(Neenah, WI)
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Family
ID: |
39760669 |
Appl.
No.: |
11/821,390 |
Filed: |
June 22, 2007 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20080314393 A1 |
Dec 25, 2008 |
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Current U.S.
Class: |
128/865; 381/328;
181/135 |
Current CPC
Class: |
A61F
11/08 (20130101); A61F 11/10 (20130101) |
Current International
Class: |
A61F
11/00 (20060101); A61B 7/02 (20060101); H04R
1/02 (20060101) |
Field of
Search: |
;128/866,867,864-865
;181/129,130,134,135 ;D24/106 ;381/322,328 |
References Cited
[Referenced By]
U.S. Patent Documents
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886002 |
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0 036 422 |
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EP |
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0 059 912 |
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EP |
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WO |
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Other References
American Society for Testing Materials (ASTM) Designation:
D2856-94, "Standard Test Method for Open-Cell Content of Rigid
Cellular Plastics by the Air Pycnometer," pp. 143-148, published
May 1994. cited by other .
American Society for Testing Materials (ASTM) Designation:
D3574-05, "Standard Test Methods for Flexible Cellular
Materials--Slab, Bonded, and Molded Urethane Foams," pp. 1-25,
published Aug. 2005. cited by other .
"How Foam Firmness Affects Performance," In Touch.RTM.--Information
on Flexible Polyurethane Foam, vol., No. 3, published by
Polyurethane Foam Association, Jul. 1994, pp. 1-3. cited by other
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"Pura-Cones.TM. Foam Earplugs," Moldex-Metric, Inc., Culver City,
CA, Internet web page
"http://www.moldex.com/foamplugprod/puracones.htm", viewed and
printed Jun. 20, 2007. cited by other .
"Traffic Cones.RTM. Foam Earplugs," Moldex-Metric, Inc., Culver
City, CA, Internet web page
"http://www.moldex.com/foamplugprod/trafficcones.htm", viewed and
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dated Nov. 3, 2008. cited by other.
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Primary Examiner: Bianco; Patricia M
Assistant Examiner: Hawthorne; Ophelia
Attorney, Agent or Firm: Klembus; Nancy M.
Claims
What is claimed is:
1. A self-conforming sound attenuation earplug comprising: a stem
made of a stem material and having a stem ear end and an opposite
stem user end; at least one support joined with the stem and made
of a support material and having at least a part of the support
located between the stem ear end and the stem user end; at least
one stiffening rib extending between the support and the stem: a
shell made of a shell material and engaging an outer circumference
of at least a portion of the support and encircling at least a
portion of the stem wherein a space is formed between an inner
circumference of the shell and an outer circumference of the stem
and the shell has a shell ear end and an opposite shell user end
and a tapered exterior that increases in circumference when moving
from the shell ear end to the shell user end and wherein the
support material is a deformable-resilient material; wherein the
shell and the support are formed independent of one another and
composed of a different type of material, and wherein the support
extends radially outward from the stem and over a portion of the
stem, and wherein the stem material and the support material each
comprise a deformable-resilient material having a Shore A Durometer
Hardness value between about 10 and about 45.
2. The earplug of claim 1 wherein the support has a support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 10 degrees to 90 degrees is formed between
the two axes.
3. The earplug of claim 2, wherein the support has a support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 10 degrees to 40 degrees is formed between
the two axes.
4. The earplug of claim 3 wherein the support has the support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 15 degrees to 35 degrees is formed between
the two axes.
5. The earplug of claim 2 wherein the support has a support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 60 degrees to 80 degrees is formed between
the two axes.
6. The earplug of claim 1 wherein the shell material has a shell
Softness Rating between 0.3 psi [0.02 Kg/cm.sup.2] and 10.0 psi
[0.73 Kg/cm.sup.2].
7. The earplug of claim 6 wherein the shell material has a shell
Softness Rating between 0.3 psi [0.02 Kg/cm.sup.2] and 4.0 psi
[0.29 Kg/cm.sup.2].
8. The earplug of claim 1 wherein the first support comprises a
continuous cup-shaped member.
9. The earplug of claim 1 wherein the support comprises a
continuous cup-shaped member and the cup-shaped member has a
spherical cross-sectional shape.
10. The earplug of claim 1 wherein the shell material comprises a
wall of substantially uniform thickness from the shell user end to
the shell ear end.
11. The earplug of claim 1 wherein the stem and the support are
composed of the same type of material.
12. The earplug of claim 1 wherein the support material is a
thermo-plastic elastomer polymeric material.
13. The earplug of claim 1 wherein the shell is formed of a
cellular foam.
14. The earplug of claim 1 wherein the stem and the support are
each formed independently and join together in a fitted
relationship.
15. A self-conforming sound attenuation earplug comprising: a stem
made of a stem material and having a stem ear end and an opposite
stem user end; at least one support joined with the stem and made
of a support material and having at least a part of the support
located between the stem ear end and the stem user end; a shell
made of a shell material and engaging an outer circumference of at
least a portion of the support and encircling at least a portion of
the stem wherein a space is formed between an inner circumference
of the shell and an outer circumference of the stem and the shell
has a shell ear end and an opposite shell user end and a tapered
exterior that increases in circumference when moving from the shell
ear end to the shell user end and wherein the support material is a
deformable-resilient material; wherein the shell and the support
are formed independent of one another and composed of a different
type of material, and wherein the support extends radially outward
from the stem and over a portion of the stem, and wherein the stem
material and the support material each comprise a
deformable-resilient material a Shore A Durometer Hardness value
between about 10 and about 90.
16. The earplug of claim 15 wherein the shell material has a shell
Softness Rating between 0.3 psi [0.02 Kg/cm.sup.2] and 10.0 psi
[0.73 Kg/cm.sup.2].
17. The earplug of claim 16 wherein the shell material has a shell
Softness Rating between 0.3 psi [0.02 Kg/cm.sup.2] and 4.0 psi
[0.29 Kg/cm.sup.2].
18. The earplug of claim 15 wherein the support has a support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 10 degrees to 90 degrees is formed between
the two axes.
19. The earplug of claim 18 wherein the support has a support
longitudinal axis and the stem has a stem longitudinal axis and an
angle in the range of 60 degrees to 80 degrees is formed between
the two axes.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to devices for location in
an ear canal, and more particularly to earplugs that are
insertable, self-conforming and used for noise reduction, e.g.,
high sound attenuation.
The need for adequate hearing protection in high noise environments
has long been recognized among those concerned with health and
safety issues, and much effort has gone into providing such
protection. However, most experts in this field would acknowledge
that this effort has not been completely successful. Protective
devices have proliferated yet remain mediocre in performance,
particularly in terms of a comfortable fit over a longer period of
time (e.g., at least 4 hours). Workers in high noise environments
who should use these devices often do not, or use them only under
duress from their employers, and then do so improperly because they
value comfort over a proper, likely uncomfortable, fit. Individuals
that work in high noise environments rarely understand that the
effects of high noise exposure are not limited to the moment but
are cumulative as well. The lack of worker compliance with safety
rules is exacerbated by the fact that currently available hearing
protection devices are often uncomfortable, clumsy to use, and/or
perform poorly due to improper insertion in the ear canal.
Additionally, human ear canal sizes vary from 7 to 8 millimeters in
diameter for "small" canals, to 9 to 10 millimeters in diameter for
"medium" canals, to 11 to 12 and as much as 14 millimeters for
"large" canals. Fortunately, as hearing protection devices become
more comfortable and/or fit better across a broader range of canal
sizes, worker compliance with their use should also improve.
For example, existing disposable roll-down foam earplugs can be
uncomfortable when worn over longer periods of time, are difficult
to properly insert, and/or do not readily stay in place for a
longer period of time. Common disposable foam earplugs require the
user to compress the area of the plug and insert it into the ear
canal where it then attempts to re-expand. This method can cause
discomfort for people with ear canals that are not the largest ones
contemplated for that earplug's intended use, in that the more
compressed the earplug in an ear sized smaller than "large", the
greater the earplug's exerted outward force toward re-expansion.
Such a roll-down type earplug may be found, for example, in U.S.
Pat. No. 6,105,715 to Knauer.
Further, existing disposable foam earplugs require the user to roll
the foam between their fingers to compress the foam to a sufficient
size for proper insertion. If this step is not done, or is
insufficiently done, the earplug is often inserted improperly
(i.e., usually meaning not inserted enough into the ear canal) so
as to not provide optimal protection (i.e., not optimal often being
as little as 25% of the earplugs' advertised Noise Reduction Rating
("NRR") as determined by industry standards). And, even when the
earplug is initially inserted properly, it is common for workers in
a work environment that requires continuous earplug use to
experience discomfort from the pressure exerted from the residual
expansion forces of the rolled earplug. The discomfort is sometimes
relieved by the partial removal of the earplug from the ear canal,
thereby compromising the sound attenuating protection of the
device. Also, if the user has dirty hands when compressing the
earplug, dirt and/or germs are then put into the ear canal with the
inserted earplug.
As with roll-down type earplugs, push-in type earplugs attenuate
sound by causing an occlusion within the car canal, thus
obstructing the passage of sound there-through. Push-in type
earplugs generally comprise an attenuating annular portion and a
rigid to semi-rigid stem portion typically extending therefrom or
embedded therein and used as an insertion means. The sound
attenuating portion is typically of a soft compressible material.
The rigid to semi-rigid portion may be composed of any material
with sufficient rigidity as required to overcome the insertion
pressure of the earplug. To insert the push-in type earplug, the
user grasps the rigid/semi-rigid portion (or an end of the earplug
proximate thereto), positions the earplug proximate the ear canal
opening, and inserts the sound attenuating portion into the canal
by pushing with the rigid/semi-rigid portion. The sound attenuating
portion compresses, as necessary, upon entry into the ear canal and
is held therein by a friction fit, occluding the canal and
providing sound attenuation. Such a push-in type earplug may be
found, for example, in U.S. Pat. Nos. 4,867,149 and 5,188,123 to
Falco and Gardner Jr., respectively
Push-in type earplugs are considered by many to provide easier
insertion than other types of plugs. As discussed above, the wearer
simply grasps the rigid or semi-rigid portion (or the end of the
earplug proximate thereto) and inserts the sound attenuating
portion at the opposite end into the car canal, lodging the earplug
therein and, hence, occluding the canal. However, while allowing a
simplistic insertion, the push-in type car plug typically does not
yield the higher attenuations often provided by roll-down type
earplugs. This may be because the push-in plug typically has a
lesser surface area contacting the ear canal when inserted therein,
or perhaps because the push-in plug wrinkles or folds during
insertion creating leaks, or, further, because the push-in plug
does not stay firmly in place during use and backs slightly out of
the ear canal.
Therefore, existing roll-down and push-in type earplug materials
and constructions do not have the ability to simultaneously
accommodate each of: adequate insertion means, comfortable fit and
sound attenuation. Accordingly, a hearing protection device is
needed which is easy to insert, comfortable to the user during a
longer period of use, and provides desired sound attenuation. The
applicants have surprisingly invented such a device, as discussed
further herein.
SUMMARY OF THE INVENTION
Various definitions used throughout the specification and claims
are provided first, followed by a description of various aspects of
the invention.
As used herein, "deformable-resilient" means the property of a
material or composite material that permits it to be deformed in
size and/or shape: (i) to 70% or less of its original size and/or
shape by a sufficiently large force applied to cause deformation
and (ii) then such recovers at least about 80% of its original size
and shape no later than two minutes after removal of the force
causing the deformation.
As used herein, "non-resilient" means the opposite of
resilient.
As used herein, "Softness Rating" means the Indentation Force
Deflection ("IFD") value for a flexible cellular material as
determined using the standardized test method described in
ASTM-D-3574, American Society for Testing and Materials, 2005, Test
B.sub.1--Indentation Force Deflection Test--Specified Deflection.
The flexible cellular material used to construct the shell material
of the invention is made into 5 test samples, each being a flat
piece of foam having dimensions of 380 millimeters wide by 380
millimeters long by 100 millimeters thick. Each sample is tested
according to the test method to determine its IFD in pounds per
square inch (psi) and its equivalent measures in other scales, at
25% deflection. In the test, each sample is preflexed to 75% of its
thickness at 230 millimeters/min, and then allowed to rest with the
flex force removed, for six minutes. For the measured test then,
the preflexed sample is indented at 50 millimeters/min to 25% of
its total thickness and the force in newtons observed at that
deflection after 60 seconds. The average of the IFD values for the
five samples is the Softness Rating for that shell material.
In one aspect of the present invention, there is provided a
self-conforming sound attenuation earplug for location in an ear
canal. The device includes a stem made of a stem material and
having a stem ear end and an opposite stem user end. At least one
support is joined with the stem and made of a resilient support
material and has at least a part of the support located between the
stem ear end and the stem user end, where the support extends
radially outward from the stem. A shell is made of a shell material
and engages an outer circumference of at least a portion of the
support and encircles at least a portion of the stem. A space is
formed between an inner circumference of the shell and an outer
circumference of the stem. The shell has a shell ear end and an
opposite shell user end, and a tapered exterior that increases in
circumference when moving from the shell ear end to the shell user
end. At least one of the support material and the shell material is
a deformable-resilient material. The shell and the support are
formed independent of one another and composed of a different type
of material.
Other features of the invention relate to particular configurations
and characteristics of the stem, support and the shell, each alone
and in relation to each other. Still other features of the
invention will be in part apparent and in part pointed out
hereinafter as well as better understood by practice of the
invention.
It is to be understood that both the foregoing general description
and the following detailed description are exemplary and are
intended to provide further explanation of the invention claimed.
The accompanying drawings, which are incorporated in and constitute
part of this specification, are included to illustrate and provide
a further understanding of the earplug for location in an ear canal
that is the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention;
FIG. 2 is a cross-sectional view of the device in FIG. 1;
FIG. 3 is a partial cross-sectional view of an alternative support
of the present invention;
FIG. 4 is a perspective view of an alternative stem and support of
the present invention;
FIG. 5 is a partial cross-sectional view of an alternative support
of the present invention;
FIG. 6 is a top view of an alternative support of the present
invention;
FIG. 7 is a side of an alternative configuration of the present
invention;
FIG. 8 is a perspective view of the device in FIG. 7;
FIG. 9 is a perspective view of an alternative configuration of the
present invention;
FIG. 10 is an exploded view of the device in FIG. 9;
FIG. 11 a perspective view of an alternative configuration of the
present invention;
FIG. 12 is an exploded view of the device in FIG. 11;
FIG. 13 is a perspective view of an alternative configuration of
the present invention;
FIG. 14 is a perspective view of the support and stem of the device
in FIG. 13;
FIG. 15 is an exploded view of the device in FIG. 13; and
FIG. 16 is a perspective view of the device in FIG. 1 as it is
about to be inserted in an ear canal.
Corresponding reference characters indicate corresponding parts
throughout the drawings.
DETAILED DESCRIPTION
Referring now to the drawings and in particular FIGS. 1-4 and 16
for example, there is depicted a earplug 10 for location in an ear
canal 12. Particularly in FIG. 16, there is seen outer ear 13
joined to the portion of the ear canal 12 through which the device
10 is inserted for use, and where the ear drum (not seen) is
located at the other end of the ear canal spaced from the device
when inserted into the ear canal. Device 10 includes a stem 20, a
support 30, and a shell 50. Stem 20 is made of a stem material and
includes a stem ear end 22 and an opposite stem user end 24.
At least one support 30 is joined with stem 20, and advantageously,
two, three, four, or more supports. Support 30 is made of a
resilient support material, and at least a part of the support is
located between the stem ear end 22 and the stem user end 24,
relative to a side portion of the stem along the stem longitudinal
axis 28. The support extends radially outward from the stem.
Support 30 and stem 20 could be formed together of one material
(e.g., most of the Figures), or formed of separate materials that
are sequentially formed together (e.g., sequential injection
molding steps, not specifically shown), or formed separately and
then joined together by any conventional means (e.g., FIGS. 13-15),
such as, adhesive, chemical or heat or other similarly resulting
mechanical bonded relationship.
A shell 50 made of a shell material engages an outer circumference
31 of at least a portion of the support. The shell also encircles
at least a portion of the stem, often not directly but relative
thereto, and a space 56 is formed between an inner circumference 58
of the shell and an outer circumference 26 of the stem. The shell
50 has a shell ear end 52, an opposite shell user end 54, and a
tapered exterior that increases in circumference when moving from
the shell ear end 52 to the shell user end 54.
The following two features of the device, in combination with other
requirements of the invention as discussed herein, are critical to
it achieving its advantageous use over existing in-ear located
earplug devices, and in particular attaining the proper balance of
fit, comfort and sound attenuation, for enhanced user compliance
over longer periods of time. First, at least one of the support
material and the shell material is a deformable-resilient material.
And second, the shell and the support are formed independent of one
another and composed of a different type of material.
Without being limited to a theory of understanding, these combined
features allow each of the shell and the support to do what they do
best, and not make one perform a contradictory role. The applicants
have inventively discovered that the ability to effectively seal
the ear canal with a hearing protection device is related to the
ability (i) to keep the earplug surface in continuous contact with
the ear canal as the earplug is reduced in size during insertion
and (ii) to conform the earplug surface to the irregularly shaped
ear canal. The resistance to deformation by the earplug will
determine how much force is therefore generated from the
dimensional reduction in at least a portion of the earplug shape
and/or size as it is inserted into the ear canal. The resistance to
deformation is due to the mechanical properties of the earplug
material (e.g. durometer, Softness Rating, and/or density) as well
as the physical cross sectional shape of the earplug
components.
More specifically, and as embodied in the present invention like
never before possible, shell 50 can now more so operate as a soft,
cover-like material that itself exerts more limited outward
pressure on ear canal 12, thereby enabling it to be tailored to
addressing the comfort needs of device 10. For example, shell 50
can help to disperse the local forces of the adjacent support over
a broader area thus minimizing the actual force transmitted by the
support on any particular point of the ear canal. Also, shell 50
can serve as a cushion against the ear canal which provides comfort
for the earplug that is resting against the ear canal over longer
periods of use. Still further, shell 50 can act as a gap filler
within the ear canal to create a better seal between the earplug
and the ear canal.
Complementarily, support 30 made of resilient material now more so
operates as a supportive member to the shell. The support 30
provides additional shape integrity for the shell and through this
the radially outward force of the support enables a more consistent
force profile to the overall device both before and when located in
ear canal 12. This can also enhance sealing of the shell against
the ear canal when in the ear canal, thereby enabling it to be
tailored to addressing the fit needs of device 10 in a more
comfortable way.
Further in this regard, though not required, there are other ways
to enhance the just discussed features. For example, at least a
portion of the support and the shell may be in an independent
relationship relative to each other. While shell 50 must in some
areas be more permanently joined with support 30 and/or stem 20 so
the device stays together as a single unit, shell 50 can be joined
such that at least a portion of the outer circumference 31 of the
support can move relative to the adjacent inner circumference 58 of
the shell when shell 50 is engaged with support 30. As another
example, the support may continuously exert a radial outward force
upon the shell where so engaged with the shell both before and when
the device is located in the ear canal. As yet another example, the
shell material may have a shell Softness Rating that is between 0.3
psi [0.02 Kg/cm.sup.2] and 10.0 psi [0.73 Kg/cm.sup.2].
Advantageously, though not required, the Softness Rating could be,
in order of increased softness (and thus preference), between 0.3
psi [0.02 Kg/cm.sup.2] and 7 psi, and between 0.3 psi [0.02
Kg/cm.sup.2] and 4.0 psi [0.29 Kg/cm.sup.2]. Through each of these
additional features, the support can provide even better customized
sealing of the shell against the ear canal and enhance fit, while
also allowing the shell to maintain comfort needs.
As yet another example, there is the positioning of support 30
relative to stem 20. As seen in FIGS. 1-6 and particularly 5 for
discussion here, the support can have support longitudinal axis 34
and the stem can have stem longitudinal axis 28, such that angle 36
is formed between the two axes in the range of, and in increasing
advantage increments of, 50 degrees to 90 degrees, 60 degrees to 80
degrees, or 65 degrees to 75 degrees. As see in FIGS. 7-15 and
particularly 10 for discussion here, the support can have support
longitudinal axis 34 and the stem can have stem longitudinal axis
28, such that angle 36 is formed between the two axes in the range
of, and in increasing advantage increments of, 10 degrees to 40
degrees, 15 degrees to 35 degrees, or 20 degrees to 30 degrees.
As still another example, the device may include features related
to support and shell lengths. Referring to FIGS. 3 and 12 for
example, there is seen the support with a support length 38 and the
shell with a shell length 68. The support length is measured from
the outmost tip of the support to where the support joins the stem.
The shell length is measured from its most distal end points of
shell ear end 52 to shell user end 54. The support length can be
greater than the shell length. Alternatively, the support length
can be at most one-half that of the shell length.
As yet another example, the device may include features related to
the shell thickness which can provide additional comfort when
inserting and/or using device 10. Referring to FIG. 2, for example,
at least one of the support member and the shell member may have a
portion that is a continuous annular cross section ring positioned
around and orthogonal to the stem longitudinal axis. When such ring
is the shell, the ring (i.e., the wall of the shell located any
where between the shell user end and the shell ear end), may have a
radial thickness between 0.5 millimeters and 4 millimeters, more
advantageously between 1.0 millimeters and 3.0 millimeters, and yet
more advantageously between 1.5 millimeters and 2.0 millimeters.
Additionally or alternatively, the shell material may be a wall of
substantially uniform thickness from the shell user end to adjacent
the shell ear end, and the shell ear end at 66 may have a thickness
in the range of 2 millimeters to 10 millimeters in front of the
stem ear end. This shell ear end thickness at 66 is measured
relative to stem longitudinal axis 28 from the front most tip of
stem ear end 22 to the front most tip of shell ear end 52. Still
more advantageous in this regard, the shell ear end thickness at 66
may be in the range of 4 millimeters to 8 millimeters.
In other aspects of the invention there is provided various
configurations for support 30. Referring to FIGS. 1-2 for example,
support 30 can be a continuous cup-shaped member 40. Seen in FIG. 4
for example, the support can be a continuous cup-shaped member with
at least one finger 42 extending from the cup-shaped member.
Referring to FIGS. 1-2 again for example, support 30 can be
continuous cup-shaped member 40 where the cup-shaped member has a
spherical cross-sectional shape. In reference to FIGS. 3, 5 and 6
for example, at least one stiffening rib 70 can extend between
support 30 and stem 20, and the rib can be planar as seen in FIG.
5.
The support can be made of a homogeneous material or a composite
material, and may include one or more layers. Such materials may be
polyurethane santoprene, polyethylene, or polypropylene, or other
thermoplastic elastomer polymeric or other rubber or resilient
material having a Shore A Durometer Hardness value between about 10
and about 90, and with a material thickness between about 0.20
millimeters and about 5 millimeters.
The stem may be made of the same type of materials as used for the
support, for example, being composed of a deformable-resilient
material having a shore A Durometer hardness value between about 10
and about 90, and with a stem material diameter between about 2
millimeters and about 8 millimeters.
The shell may be made of polyurethane santoprene, polyethylene, or
polypropylene, or other thermo-plastic elastomer polymeric
materials, hydro-entangled materials, air-entangled materials,
paper materials such as tissue, toilet paper, or paper towels,
waxed paper materials, coform materials, film or plastic materials
such as those used to wrap food, or any other generally soft and
pliable material that has the desired characteristics of the
present invention. Furthermore, laminated or plied together
multi-layer materials of two or more layers of any of the preceding
materials may be employed. For example, the shell can be made of
visco-elastic foam material which has various material properties.
The density of the shell material can be about 6 to 20_lbm/ft.sup.3
as measured by ASTM D-3574-05. More desirably, the density of the
shell material can be about 10 to 15 lbm/ft.sup.3. The foam can be
further described by the cell size and desirably can have a minimum
cell size >80 pores per inch and more desirably >100 pores
per inch. The cell structure can be further defined by the cell
structure which desirably can be between 30-70% open cells and more
desirably between 40-60% open cells, as measured by Standard Test
Method for Open-Celled Content of Rigid Cellular Plastics by the
Air Pycnometer, ASTM 2856-94, American Society of Testing and
Materials, Annual Book of ASTM Standards, 1998. The recovery time
for the foam material can be desirably between 2 and 120 seconds,
but more desirably between 2 and 20 seconds, as measured by a
standard test for the recovery time that is found in ASTM 3574-05,
previously cited. The water absorption of the foam can be desirably
<20% and more desirably <5%, as measured by standard test
methods such as found in ASTM D570.
Other aspects of the invention concern the construction of the stem
and the support relative to one another. For example, and seen in
FIGS. 2, 3 and 5, the stem and the support may be composed of the
same type of material. Alternatively, as seen in FIGS. 13-15, the
stem and the support can be each formed independently and then
joined together in a fitted relationship.
Referring to FIG. 7, device 10 may include a lanyard 80 joined with
stem 20, or other similar connection means for a variety of
reasons, e.g., easy location when not in an ear canal, to help
remove from the ear canal, to keep from falling into a user's work
space, or the like.
In practice, device 10 may be used as follows. The user grasps the
stem user end 24 (e.g., by a user's thumb and/or finger(s) or the
like) and then locates the shell ear end adjacent the user's outer
ear 13. The user then gently pushes the device into the ear canal
12 until is fits snuggly and yet is comfortable. So positioned in
the ear canal, the device can perform sound optimization such as
noise reduction and/or acoustic enhancement for the user, as
desired. In particular, the final in-ear position is determined by
the user's particular ear canal shape and size and is therefore
self-conforming and customizable each time it is used. For removal,
the user simply pulls the device out of their ear, with or without
a slight twisting of the stem to aid in more gentle removal. Also,
with the features of the present invention it is made of
sufficiently substantial materials and design so as to allow for
multiple uses.
While not required, it may be advantageous for sound enhancement,
e.g., not only taking advantage of sound reduction capabilities but
also hearing aid type capabilities. In this way, device 10 can be
configured (not shown) to locate a microphone or the like in device
10 and help bring desired sound into the ear canal and/or locate a
microphone in the ear canal better, e.g., via stem 20 and/or
support 30.
As various changes could be made in the above constructions and
methods, without departing from the scope of the invention, it is
intended that all matter contained in the above description and
shown in the accompanying drawings shall be interpreted as
illustrative and not in a limiting sense.
When introducing elements of the invention or the preferred
aspect(s) thereof, the articles "a", "an", "the" and "said" are
intended to mean that there are one or more of the elements. The
terms "comprising", "including" and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements.
* * * * *
References